****

DESCRIPTION

The present solution relates to an apparatus for making containers filled with a liquid and sealed, starting from a web of packaging material.

In particular, the apparatus described herein is of the type comprising: a forming unit for folding the web of packaging material into a tubular shape about a main axis parallel to a direction of feed of the web so as to set two, opposite, longitudinal edges of the web in a condition where they overlap one another and where one of the two edges is closer to the main axis and defines an inner edge and the other of the two edges is farther away from the main axis and defines an outer edge; and a fixing device for fixing together the two, inner and outer, edges of the web in an area of connection of the two, inner and outer, edges that extends along the main axis.

In operation of such an apparatus there is the need to adjust a width of the area of connection of the two longitudinal edges both for preparation of the apparatus for the production of containers with a new format and during the production cycle to compensate for possible displacements of the two longitudinal edges from their pre-set positions.

Available on the market are known solutions for adjusting the width of the aforesaid connection area, which envisage a roller prearranged for acting in the forming unit on an outer side of the tube of material opposite to the connection area mentioned above so as to squeeze the tube itself with variable intensity, indirectly conditioning the position of the two edges of web and thus adjusting the width of the connection area.

The present applicant has noted that apparatuses for making containers like the ones described undergo frequent cycles of cleaning and sterilization, designed to counter any contamination coming from the external environment and thus ensure that the product is processed in a sterile and aseptic environment. As a consequence of these cleaning and sterilization cycles, likewise frequent are machine downtimes, which reduce, at times drastically, the volume of production. The present applicant has likewise noted that the aforesaid contamination occurs in general when it is necessary to gain access to the forming unit, i.e., to remove the barriers or deactivate the mechanisms of isolation of the closed aseptic chamber, within which the forming unit is located, with the result that the forming unit is exposed to the external environment.

The present applicant has moreover found that the drawbacks highlighted above are particularly accentuated whenever it is necessary to carry out adjustment of the width of the connection area. In the solutions according to the prior art, the roller prearranged for acting on an outer side of the tube of packaging material is unable to guarantee precise, repeatable, and controllable adjustment in a unique way of the position of the edges of the web, given that it acts in an indirect way on their mutual position. It is thus necessary to gain access to the forming unit frequently to intervene on the roller itself and restore proper operating conditions.

The present applicant has hence noted that the possibility of gaining access to the forming unit, which is the main cause of contamination coming from the external environment and of the loss of asepsis by the apparatus, could be avoided by getting the means for adjusting the width of the connection area to act on the edges of the web in a direct way. In particular, the present applicant has found that adjustment of the width of the connection area is particularly reliable and repeatable when the operation is carried out on just the inner edge of the web.

In the present description and in claims annexed thereto, some terms and phrases are intended to have, except where explicitly indicated otherwise, the meaning given in the ensuing definitions.

By the term "longitudinal edge" of a web is meant an edge of said web that extends along the length of the web; in the particular cases where a web is wound off reel, the longitudinal edge extends in the direction of feed of the web.

By the terms “fix”, “fixing”, in reference to two edges of a web, is meant the operation of getting the two edges to adhere together in a definitive way.

By the term “width”, in reference to an area, is meant the smaller dimension of this area; in the particular cases where reference is made to the “width” of a web or part or area of web processed in a forming unit, there is meant the smaller dimension of the web or part or area of web that develops in a direction orthogonal to the main axis of the forming unit.

In a unit for processing, for example forming, a web that advances in a direction of feed, a first station is considered “upstream” of a second station when the first station precedes the second station with reference to the direction of feed of the web; vice versa, the second station is considered “downstream” of the first station in so far as it follows the first station once again with reference to the direction of feed of the web.

By the term "parallel" is meant a substantial parallelism between two elements, comprising both the ideal case where these elements are arranged with respect to one another so as to form a zero angle and more frequent cases where the two elements are arranged with respect to one another so as to form an angle that is non-zero but, however, is negligible or unimportant for the purposes of operation according to the present solution.

In a first aspect, the present invention concerns an apparatus for making containers filled with a liquid and sealed, preferably starting from a web of packaging material.

Preferably, the apparatus comprises a forming unit for folding the web of packaging material, preferably into a tubular shape, about a main axis, preferably parallel to a direction of feed of the web. Preferably, the forming unit thus sets two, opposite, longitudinal edges of the web in a condition where they overlap one another and where one edge of the two longitudinal edges is closer to the main axis and defines an inner edge and the other edge of the two longitudinal edges is farther away from the main axis and defines an outer edge.

Preferably, the apparatus comprises a fixing device for fixing together the two, inner and outer, edges of the web, preferably in an area of connection of the two, inner and outer, edges. Preferably, the connection area extends along the main axis.

Preferably, the apparatus comprises an adjustment device for adjusting a width of the connection area. Preferably, said adjustment device comprises a backing member. Preferably, the backing member is positioned upstream of the fixing device. Preferably, the backing member is configured to insert itself between the two, inner and outer, edges of the web. Preferably, the backing member is prearranged for engaging the inner edge. Preferably, the backing member is mobile according to one or more degrees of freedom in a plane preferably orthogonal to the main axis.

Thanks to the backing member, which inserts itself between the two, inner and outer, edges of the web for engaging the inner edge and is able to move according to one or more degrees of freedom, for example in a plane orthogonal to the main axis, the adjustment device is able to operate directly and position precisely the inner edge with respect to the outer edge of the web so as to determine a connection area of pre-set width. The displacement of the edge performed by the backing member of the device results directly in a variation of the width of the connection area, so that adjustment of this width afforded by the device is precise, reliable, and repeatable.

In a second aspect, the present invention concerns a process for forming a web of packaging material for making containers filled with a liquid and sealed.

Preferably, the process comprises the step of moving the web of packaging material in a direction of feed.

Preferably, the process comprises the step of folding the web of packaging material, preferably into a tubular shape, about a main axis, preferably parallel to the direction of feed. Preferably, the process makes it possible to set two, opposite, longitudinal edges of the web in a condition where they overlap one another and where one edge of the two longitudinal edges is closer to the main axis and defines an inner edge and the other edge of the two longitudinal edges is farther away from the main axis and defines an outer edge.

Preferably, the process comprises the step of fixing together the two longitudinal edges of the web, preferably along an area of connection of the inner and outer edges that extends preferably along the main axis.

Preferably, the process comprises the step of adjusting a width of the connection area.

Preferably, the step of adjusting the width of the connection area includes inserting a backing member between the two, inner and outer, edges of the web, preferably, in a position upstream of the connection area in the direction of feed of the web.

Preferably, the step of adjusting the width of the connection area includes engaging via the backing member the inner edge of the web.

Preferably, the step of adjusting the width of the connection area includes moving the backing member in a plane, preferably orthogonal to the main axis, for bringing about a variation of the width of the connection area.

Thanks to the characteristics of the process according to the invention, the inner edge is positioned in a precise way with respect to the outer edge of the web by the adjustment device so as to adjust the width of the area of connection of the two edges in a precise, reliable, and repeatable way.

According to one or more of the aforesaid aspects, the present solution may comprise one or more of the characteristics referred to in what follows.

In one or more embodiments, the backing member is formed by a cylindrical body, the geometrical axis of which is preferably orthogonal to the main axis.

The cylindrical shape of the backing member, in particular with geometrical axis orthogonal to the main axis, i.e., to the direction of feed of the web, presents the advantage of reducing friction and getting the inner edge of the web that advances in the direction of feed to slide on the backing member itself. In this way, the likelihood of the backing member damaging, for example scratching or tearing, the aforesaid inner edge is minimal or even zero.

In one or more embodiments, the backing member may be mobile in the plane orthogonal to the main axis so as to vary the distance of the inner edge of the web from the main axis.

The forming unit normally constrains the geometry of the web of packaging material when it is folded into a tubular shape; in particular, the cross section (with respect to the main axis) of the web folded into a tubular shape has a perimeter smaller than or equal to a maximum perimeter defined by a plurality of components of the forming unit, typically arranged in a circle to form a through opening, against which the outer surface of the web folded into a tubular shape comes to rest. Considering these geometrical constraints, when the longitudinal inner edge of the web is brought up to or moved away from the main axis by the backing member, the perimeter of the cross section of the web folded into a tubular shape decreases or, respectively, increases up to the maximum perimeter, consequently bringing about a respective increase or decrease of the width of the area of connection, i.e., overlapping, of the edges.

In one or more embodiments, the backing member is rotatable about an axis of rotation, preferably parallel to the main axis.

In one or more embodiments, the backing member is mobile along an axis of translation, preferably transverse to a direction tangential to the inner edge of the web.

In one or more embodiments, the adjustment device comprises a slide mobile on a guide along the axis of translation.

In one or more embodiments, the backing member is mounted on a mobile slide and is rotatable about the axis of rotation.

In one or more embodiments, the device comprises a first drive unit for governing the movement of the slide along the axis of translation.

In one or more embodiments, the device comprises a second drive unit for governing rotation of the backing member about the axis of rotation.

In one or more embodiments, the apparatus comprises a housing that delimits an inner chamber. Preferably, the forming unit is provided inside the inner chamber. Preferably, a mobile slide of the adjustment device is set inside the inner chamber.

In one or more embodiments, the first drive unit comprises an electromechanical actuator. In one or more embodiments, the second drive unit comprises an electromechanical actuator. In one or more embodiments, the first and second drive units each comprise an electromechanical actuator.

In one or more embodiments, the electromechanical actuator can be governed by means of a control station, preferably, external to the housing.

Thanks to these characteristics, the adjustment device can be operated without any need to stop the apparatus and/or gain access into the aforesaid inner chamber in which the forming unit is located. In this way, there is the advantage of reducing machine downtimes, all the more in so far as hygiene and asepsis of the inner chamber are not jeopardized, and no additional sterilization cycles are required.

In one or more embodiments, the first drive unit comprises a manual actuator. In one or more embodiments, the second drive unit comprises a manual actuator. In one or more embodiments, the first and second drive units each comprise a manual actuator.

The presence of manual actuators makes it possible to carry out adjustment of the position of the backing member on the basis of the experience of the skilled operator, who determines a substantially optimal position of the backing member to have a pre-set, for example visually acceptable, width of the area of connection of the edges of the web. In particular, when the manual actuators are in combination with the electromechanical actuators, they make it possible to carry out an initial manual adjustment that brings the backing member into a first position deemed optimal by the skilled operator, thus simplifying the work of the electromechanical actuators, which carry out a smaller number of cycles for adjusting the position of the backing member. In addition, in the event of malfunctioning or breakdown of the electromechanical actuators, the manual actuators make it possible to continue adjusting the position of the backing member, i.e., the width of the area of connection of the edges of the web, without stopping the forming unit, bringing to a conclusion the production cycle and being able to intervene subsequently to solve the problem, thus minimizing rejects and machine downtimes.

In one or more embodiments, the manual actuator comprises a manual-adjustment member, which is preferably rotatable and is preferably positioned on the outside of the housing.

In one or more embodiments, the manual actuator comprises a driven member, which is preferably rotatable. Preferably, the driven member is designed to drive movement of the slide along the axis of translation. Preferably, the driven member is designed to drive rotation of the backing member about the axis of rotation.

In one or more embodiments, the manual actuator comprises a connection element that is preferably flexible, which operatively connects together the manual-adjustment member and the driven member.

Thanks to these characteristics, the adjustment device can be operated without any need to stop the apparatus and/or gain access to the aforesaid inner chamber, where the forming unit is located.

In one or more embodiments, the fixing device is set downstream of the forming unit in the direction of feed.

In one or more embodiments, the fixing device is set at the end of the forming unit in the direction of feed.

In one or more embodiments, the apparatus comprises a detection unit for detecting the width of the connection area.

In one or more embodiments, the apparatus comprises a monitoring station, preferably configured to generate data and/or images indicating the width of the connection area, preferably on the basis of signals coming from a detection unit.

In one or more embodiments, the apparatus comprises a control unit, preferably configured to control the adjustment device, preferably as a function of signals coming from a detection unit.

In one or more embodiments, moving the backing member comprises varying a distance of the inner edge of the web from the main axis.

In one or more embodiments, the backing member inserted between the two, inner and outer, edges of the web is moved according to a movement of rotation about an axis of rotation, preferably parallel to the main axis.

In one or more embodiments, the backing member inserted between the two, inner and outer, edges of the web is moved according to a movement of translation along an axis of translation, preferably transverse to a direction tangential to the inner edge of the web.

In one or more embodiments, the backing member inserted between the two, inner and outer, edges of the web is moved according to a movement of rotation about an axis of rotation, preferably parallel to the main axis. In one or more embodiments, the backing member inserted between the two, inner and outer, edges of the web is moved according to a movement of translation along an axis of translation, preferably transverse to a direction tangential to the inner edge of the web.

In one or more embodiments, the process is carried out via a forming apparatus, preferably comprising a housing that delimits an inner chamber, in which the steps of folding, fixing, and adjustment are performed.

In one or more embodiments, moving the backing member includes driving the backing member from outside a housing, preferably via an electromechanical actuator, which in turn may preferably be operated from outside the housing.

In one or more embodiments, moving the backing member includes driving the backing member from outside a housing, preferably via a manual actuator, which in turn may preferably be operated from outside the housing.

In one or more embodiments, the web is wound off a reel of packaging material.

In one or more embodiments, the backing member, when inserted between the two, inner and outer, edges of the web, is kept at a distance other than zero from the outer edge of the web.

In this way, the backing member does not act directly on the outer edge of the web, in particular on an inner wall thereof generally impermeabilized to contain and isolate appropriately a liquid substance or the like, to minimize or even rule out the likelihood of the backing member itself damaging, for example scratching or tearing, the aforesaid outer edge and jeopardizing impermeability thereof, thus bringing about an end product that has to be rejected.

In one or more embodiments, the process comprises detecting the width of the connection area via a detection unit.

In one or more embodiments, the process comprises detecting the width of the connection area via one from among an optical sensor, a video camera, and a photographic camera.

In one or more embodiments, the process comprises generating data and/or images indicating a width of the connection area.

It is pointed out that some steps of the process described above may be independent of the order of execution referred to, except where a sequentiality between two or more steps is expressly indicated as being necessary. Moreover, some steps may be optional. Furthermore, some steps of the process may be carried out in a repetitive way, or else may be carried out in series or in parallel with other steps of the process.

Farther characteristics and advantages of the solution will emerge clearly from the ensuing description with reference to the annexed drawings, which are provided purely by way of non-limiting example and in which:

- Figure 1 illustrates, according to an axonometric view, an embodiment of the apparatus described herein;

- Figure 2 illustrates a detail of Figure 1 regarding adjustment means provided in the apparatus of Figure 1;

- Figure 3 is a cross-sectional view of the apparatus of Figure 1, according to the plane III-III illustrated in Figure 1; - Figure 4 is a cross-sectional view of the apparatus of Figure 1, according to the plane IV-IV illustrated in Figure 1;

- Figure 5 is an axonometric view of the adjustment means provided in the apparatus of Figure 1;

- Figure 6 is a schematic illustration of a mode of operation of the adjustment means described herein; and

- Figure 7 is a cross-sectional view according to the plane VII- VII of Figure 6.

In the ensuing description various specific details are illustrated aimed at enabling an in-depth understanding of the embodiments. The embodiments may be obtained without one or more of the specific details, or with other methods, components, or materials, etc. In other cases, known structures, materials, or operations are not illustrated or described in detail so that various aspects of the invention will not be obscured.

The references used herein are provided merely for convenience and hence do not define the sphere of protection or the scope of the embodiments.

As anticipated above, the apparatus described herein operates for the formation of containers filled with a liquid and sealed, starting from a web of packaging material, preferably, wound off a reel.

With reference to Figure 1, the apparatus described herein - designated as a whole by the reference number 10 - comprises a forming unit 12 for folding the web 100 of packaging material into a tubular shape about a main axis I parallel to a direction K of feed of the web.

In this tubular arrangement (see Figures 6 and 7), the web 100 has, in particular, two, opposite, longitudinal edges 100A, 100B, which are not in a condition where they overlap one another, so that the edge 100A is closer to the main axis I, thus defining an inner edge, whereas the other edge 100B is farther away from the main axis I, thus defining an outer edge.

In a way in itself known, the forming unit 12 comprises a plurality of forming modules 14 that are arranged in succession along the main axis I and are prearranged for bringing about gradual folding of the web 100 about the same axis.

Once again in a way in itself known, each forming module 14 comprises a ring 14A, the axis of which is substantially aligned with the main axis I and mounted on which is a circular series of rollers 14B that are freely rotatable to contain the web 100 within a predefined substantially circular profile. From one forming module 12 to the next, the corresponding circular profile narrows to bring about progressive folding of the web along the succession of the modules 14.

The apparatus 10 comprises a housing 20 that encloses the inner chamber C within which forming of the web 100 is carried out by the forming unit 12. In the chamber C itself, filling of the tube with the product to be packaged is carried out. The chamber C is characterized by a sterile internal environment formed according to modalities widely known to the person skilled in the sector.

The apparatus 10 further comprises welding means (not illustrated) for heating and softening the mutually facing surfaces of the two edges 100A, 100B. In a way in itself known, the welding means may be induction-welding means and operate by heating the metal layer of the web 100 and, indirectly, the aforesaid facing surfaces of the two edges.

Once again in a way in itself known, on the outer side of the edge 100 there is preferably applied a strip of weldable material to facilitate adhesion between the two edges 100A, 100B.

Moreover, the apparatus 10 comprises a fixing device for fixing together the two edges 100A, 100B.

In one or more preferred embodiments, the fixing device comprises a pressure roller 22 (see Figure 2), which in operation comes to be located within the tube formed by the web of packaging material to press the two edges 100A, 100B already heated by the welding means referred to above against one another.

In a way in itself known, the pressure roller 22 is preferably located in a position corresponding to the last forming module 14 in the direction of feed K. On the other hand, the aforesaid welding means are, instead, arranged upstream of the latter forming module.

The fixing device fixes together the two edges 100 A, 100B in a connection area A that extends along the main axis I. The width L of the connection area A depends upon the degree of overlapping of the two edges 100 A, 100B. The apparatus 10 further comprises an adjustment device 40 for adjusting the width L of the connection area A of the two edges 100A, 100B of the tube.

In one or more preferred embodiments, like the one illustrated, the adjustment device 40 comprises a backing member 42, which is positioned upstream of the pressure roller of the fixing device and is configured to insert itself between the two edges 100A, 100B, engaging in particular the inner edge 100A.

The backing member 42 is mobile, preferably according to at least two degrees of freedom, in a plane orthogonal to the main axis I to vary the distance (d) of the inner edge 100 A from the main axis I, in order to adjust the degree of overlapping of the two edges 100A, 100B and, consequently, the width L of the connection area A.

In one or more preferred embodiments, like the one illustrated, the backing member is formed by a cylindrical body set with its own geometrical axis orthogonal to the main axis I.

In one or more preferred embodiments, like the one illustrated, the backing member 42 is mounted so as to be rotatable about an axis of rotation Il parallel to the main axis I on a slide 44 mobile on a guide along an axis of translation X.

The adjustment device 40 comprises: a first drive unit 46 for governing movement of the slide 44 along the axis of translation X; and a second drive unit 48 for governing rotation of the backing member 42 about the axis of rotation II.

In one or more preferred embodiments, like the one illustrated, the two drive units 46, 48 are both of a manual type.

In particular, with reference to Figure 5, the drive unit 46 comprises a motion-transmission device 46A of a screw-and-nut type, configured to drive the movement of the slide 44 along the axis of translation X. In addition, the drive unit 46 comprises a rotatable knob 46B, which is preferably set on the outer side of the housing 20 that encloses the inner chamber C. The drive unit 46 again comprises a connection element 46C, which is preferably flexible and connects the knob 46B and the motion-transmission device 46A. In various preferred embodiments, like the one illustrated, the flexible element 46C has at the end a Cardan joint 46C’, preferably a double Cardan joint, via which it connects up to the device 46A.

According to the operation of the drive unit 46, rotation of the knob 46B controls the motion-transmission device 46A, as a result of their mutual connection formed by the element 46C, and the device 46A in turn drives movement of the slide 44 along the axis of translation X. The Cardan joint 46C’ is able to limit or else prevent any possible twisting of the connection element 46C.

In one or more preferred embodiments like the one illustrated, the second drive unit 48 has a configuration corresponding to that of the drive unit 46. In particular, the drive unit 48 itself also comprises a motiontransmission device 48A of a screw-and-nut, a connection element 48C (with corresponding Cardan joint 48C’) and a rotatable knob 48B. In this case, the motion-transmission device 48A is configured to move a pin 48D along an axis of translation X’ substantially parallel to the axis of translation X. The pin 48D engages the end of a lever 48E, connected in rotation to the backing member 42 so that a translation of the pin 48D along the axis X’ brings about a corresponding rotation of the backing member 42 about the axis of rotation II.

According to operation of the drive unit 48, rotation of the knob 48B controls, via the connection element 48C, the motion-transmission device 48 A, and this in turn drives movement of the pin 48D along the axis X’, and hence rotation of the backing member 42 about the axis of rotation 11.

In preferred embodiments, like the one illustrated, the two knobs 48B, 46B may present a graduated scale to facilitate control thereof by the operator.

Figure 6 is a schematic illustration of a mode of operation of the adjustment device 40. As illustrated in Figure 6, the backing member 42 inserted itself between the two edges 100A, 100B to engage the inner edge 100A, staying at the same time at a given (non-zero) distance from the outer edge 100B. The backing member 42 is designed to keep the inner edge 100A at a distance from the main axis I such as to create a connection area A of pre-set width L.

During the operation of adjustment of the width L, the backing member 42 is governed in its two movements described above, the movement of translation along the axis X and the movement of rotation about the axis of rotation 11, to bring the inner edge 100 A at the distance from the main axis I necessary for obtaining the pre-set width L and at the same time for keeping the backing member itself 42 at a non-zero distance from the outer edge 100B, in particular from the inner side of the latter. This non-zero distance prevents the backing member 42 from possibly coming into contact with the inner side of the edge 100B that is to remain sterile.

In an alternative embodiment (not illustrated), the two drive units 46, 48 may each comprise an electromechanical actuator; for example, with reference to the embodiment illustrated in Figure 5, it is possible to provide two electric rotary motors for driving the two motion-transmission devices 46A, 48A.

In this case, the apparatus 10 may comprise a control station for governing the two electromechanical actuators, external to the housing 20; this station may envisage one or more control members, such as a knob, a joystick, a keypad, etc., that can be used by the operator.

Again, it should be noted that in one or more embodiments it is also possible to provide a manual actuator and an electromechanical actuator in combination with one another for each movement of the backing member 42, according to an arrangement whereby the manual actuator is to be used for a first rough adjustment, whereas the electromechanical actuator is designed to carry out a final fine adjustment. In addition or as an alternative, the manual actuator may be designed for emergency use, in the event of malfunctioning of the electromechanical actuator.

In one or more preferred embodiments, like the one illustrated (see Figure 6), the apparatus 10 further comprises a detection unit 60, for example a camera, for detecting the width L of the connection area A of the two edges 100 A, 100B.

In one or more preferred embodiments, the images acquired by the camera 60 can be viewed on a monitor 62 provided in a monitoring station S to enable the operator to check in real time the width L of the connection area A.

Furthermore, in one or more preferred embodiments, the monitoring station S may comprise a computer 64 configured to generate data indicating the width L on the basis of the images acquired by the camera, for example using image-processing algorithms and/or artificial intelligence.

In one or more preferred embodiments, the apparatus 10 may comprise a control unit configured to govern the adjustment device 40 as a function of the signals coming from the detection unit in order to enable automatic adjustment of the width L.

Of course, without prejudice to the principle of the present solution, the details of construction and the embodiments may vary, even significantly, with respect to what has been illustrated herein purely by way of non-limiting example, without thereby departing from the scope of the solution, as defined by the annexed claims.